Learjet 45 Simulator Project

Well, I’ve managed to fit my existing main instrument panel (MIP) skeleton in the shell. It’s good that I’m making progress, but bad that I won’t be able to fly for some time, since everything is torn apart. I had a flyable MIP outside the shell until now.

Now, I need to verify that my measurements are good and modify/create attach points and support pieces. I also need to modify the current glareshield structure. I’ve got new dimensional info and it’s not quite correct as it is.

Here I have both pedal floors in for a test fit. Just for fun, I decided to put the pedestal in too. It fits in-between like a glove! The pedestal sits up from the floor a bit higher in its final configuration, so I’ll eventually have to add a riser on the bottom. Considering I built it from plans I got elsewhere and months before I got the shell, it is a good sign that the dimensions of the shell are spot on.

Since I got version one of the pedal floors in my kit, I had to make some modifications before the install. Here you can see the starboard pedal floor in place for a test fit. The yoke columns will sit in the spot just aft of the pedal floors where the plywood base can still be seen. I will be cutting out the yoke column floor pieces next. These pieces fit between the pedal floors and the raised floor in the aft of the ‘pit.

Well, I’ve completed the raised floor in the rear of the ‘pit. Next up, the front portion, which is more complex.

OK. One more video. I couldn’t resist. This is some pretty amazing flying!

Hi all,

I’m working on the raised floor and test filling one of the shell voids with foam. I always forget,  no matter how many times I’m told, that it will EXPAND. As you can see I got a little carried away. No problems though. The cardboard I have around the edges seems to be keeping the foam from sticking to the frame.

I’ve been doing a little more flying lately. I also got my hands on a new version of After Effects. Why not have a little fun with my video camera while I’m at it? I promise to not bore you with any more random videos. I will be adding more video at some point, but more likely when my full pit is finished and I can record some ‘real’ simulated flights.

For users who can’t see the embedded video, click here.

The walls are painted! It’s strange the way the uniform color on the inside changes my perceptions. Although I know it’s just Masonite hardboard, it feels like I’m inside a real airplane now.

Bring on the foam!

I spend all this time and effort trying to get this simulator to look and feel like the real thing and look how I treat it.

For users who can’t see the embedded video, click here.

Hi,

I finally got my camera working again. You’d think by now I’d know what I was doing

The inside walls have been split and joined using bolts. It makes them smaller and easier to handle upon disassembly. Hard points have been added to the horizontal stringers. These will be used as the attach points for the outside covering.  I could probably just use the existing support skeleton for attaching the covering, but I am worried that it will introduce splitting or some other unforeseen ’problem’. As a precautionary measure, I took this route.

The next step is to figure out how to keep the spray foam from sticking to the structure–other than to the fluted inside walls, and begin shaping.